Piled surface in pattern form



Oct. 8, 1940. A. F. MESTON ET AL FILED SURFACE IN PATTERN FORM Original Filed Feb. 6, l955 4 Sheets-Sheet 1 A 'IIIIIII/IIIIIIIIIIIIIIIIII/IIIIII I I Oct. 8, 1940. A. F. MESTON ET AL 2,217,126

FILED SURFACE IN PATTERN FORM I Original Filed Feb. 6, 1935 4 Sheets-Sheet 2 1940- A. F. MESTON El AL 2,217,126

PILED SURFACE IN PATTERN FORM Original Filed Feb. 6, 1935 v 4 Sheets-Sheet 5 it. vvvvvv IIIIIIIYIII 1'1 HHHHHII HHHHHH CV WWW mm v 7 w W ,6 M w w i 2 a w 0 O a F m Av 1 a P AV AV & 10 F O Av Av m n w Oct. 8, 1940. A. F. MESTON El AL 2,217,126

FILED SURFACE IN PATTERN FORM 4 Sheets-Sheet 4' lllllllllllllllli- E Patented Oct. 8, 1940 f UNITED STATES PATENT OFFICE:

PILED SURFACE IN PATTERN FORM Original application February 6, 1935, Serial No. 5,288. Divided and this application March 20, 1937, Serial No. 132,169

' 3 Claims.

This invention relates to coating and decorating surfaces with simulated piles in pattern form and is particularly directed to the novel pile surfaced material thereby produced.

. Fibers, such as rayon flocks, can be deposited in oriented position upon an adhesive covered surface if the surface is positioned in an electric field and fibers are introduced into the electric field in unrestrained manner. The conditions required for satisfactory deposition of fibers in the piling of surfaces are described in copending applications Serial No. 692,201, A. F. Meston, filed October 4, 1933, and Serial No. 699,456, H. A, Wintermute, filed November 23, 1933.

The piles made with the apparatus and methods used and described in the applications just mentioned are quite uniform in composition and appearance. Most of the fibers stand erect, perpendicular to the surface, making piles of monotonous evenness from a decorative standpoint. It has now been found that by suitable control of the electric field by means of which the fibers are deposited, and particularly by the use of a deliberately warped or discontinuous electric field, pleasing variations and definite patterns can be obtained in the pile.

A principal purpose of the invention is the production of pile surfaced material comprising a foundation Web having a binder in its surface and fibers attached to the web by the binder which vary topically in concentration or incllna- I tion or both to form a pattern.

Apparatus useful in carrying out the invention and several embodiments of the invention, ineluding novel methods and products, are hereinafter described with particular reference to the appended drawings, in which:

Fig. 1 is a diagrammatic side view of complementary electrodes and an electric field therebetween in which fibers are being attached by the forces prevailing in a. non-uniform portion of the field;

Fig. 2 is a fragmentary view in side elevation of an assembly of electrode elements as used in the deposition of fibers in accordance with the invention;

Fig. 3 is a fragmentary plan view of what is shown in Fig. 2 taken at 3-3;

Figs. 4 and 5 are fragmentary views comparable to Figs. 2 and 3, respectively, showing the utilization of somewhat different elements in the electrode structure used with the invention;

Fig. 6 is a plan view of another arrangement of electrode elements useful in setting up a nonuniform field in accordance with the invention;

Fig. 7 illustrates in side view the forming of a patterned pile on a base sheet with still another arrangement of electrodes;

Figs. 8 and 9 are fragmentary plan and side views, respectively, of another electrode assembly that can be used advantageously with the invention;

Fig. 10 indicates, perspectively, apparatus including air jets useful in applying fibers to surfaces in accordance with the invention;

Figs. 11, 12 and 13 show with plan views, the types of patterns which can be obtained with the apparatus illustrated in Fig. 10;

Fig. 14 is a plan view of a foraminous electrode comprising corona forming elements, useful in practicing the invention;

Fig. 15 shows diagrammatically in end elevation, apparatus for utilizing the electrode she in Fig, 14;

Figs. 16, 17 and 18 are views of fragmentary portions of products made with reticulated electrodes;

Fig. 19 shows diagrammatically, in side elevation, apparatus for depositing fibers in pattern formation, by utilizing a moving field stencil;

Figs. 20 and 21 show typical forms of field stencils used with the invention;

Fig. 22 illustrates, in sideview, an adhesive applying roll with cut-away portions;

Fig. 23 shows, in sectional elevation, an electrode assembly useful in depositing fibers on a surface coated with the roll shown in Fig. 22; and

Fig. 24 is a diagrammatic view in side elevation of apparatus that permits the utilization of the various electrodes and other means illustrated in the various figures and the carrying out of the several methods of the invention to be hereinafter described.

In Fig. l, numerals i and 3 identify electrodm between which an electric field has been established; electrode l is grounded as indicated at 2 and electrode 3 is insulated from ground and connected to a source of high potential constant polarity current represented by tube rectifier 6. The so-called lines of force of the, electric field represented by lines 5 leave the electrodes perpendicular to the surface. Electrode I has a pointed or rounded top and the lines of force curve and spread out in the manner shown as they leave the small area presented by the top of the electrode. Opposing or complementary electrode 3, on the other hand, has a flat surface upon which the lines of force terminate and the lines of force in the vicinity of this electrode are straight, parallel, and uniformly distributed.

When a non-conducting sheet 3 covered with adhesive 1 is positioned between electrodes I and 3 and short fibers are freely suspended in the electric field the fibers are oriented and attached to the adhesive covered sheet parallel to the lines of force passing through the sheet at the point of attachment. Once attached they maintain the positionof original attachment and resist re-alinement by forces that may be applied subsequently. When the sheet to be piled with fibers is placed in the position marked 6', the fibers are attached in the positions 8', 3' and a uniform pile of upright fibers is obtained. But if a sheet is held against, or a short distance from, electrode I, the fibers are attached at angles to the perpendicular as indicated at 3, 8 because of the inclined positions of the lines of force 5 in this region of the electric field. For instance, the field near a point causes the fibers to become arranged like the petals of a flower.

In Figs. 2 and 3, the electrode elements over which the adhesive covered sheet I5 is positioned while being piled comprises members ID with a more or less extended top surface and members I I with very restricted or edged top surfaces. The complementary electrode I2 is preferably fiat or has an extended surface. The arrangement of the fibers in the pile made with the electric field between electrode elements Ill and II and electrode I2 is shown in Fig. 2. The fibers l3 over the extended portions ID are deposited in erect position except perhaps over the edges of elements l0, while the fibers l4 over edges II are deposited in the inclined positions shown and provide a striped effect. This pattern can be made while the sheet is moving in the direction of the arrow in Fig. 3, but if it is desired to have the stripes extend crosswise of the sheet, the electrode elements Ill and II must move at the same speed as the sheet.

In Figs. 4 and 5 the electrode assembly which influences the deposition of the fibers is made up of bars l6 and pointed members l1. Complementary electrode I8 has a fiat extended surface. The pile formed with these electrode elements, assembled as shown, comprises parallel stripes with spots between them, the stripes being formed of fibers 20 deposited over rods l6 perpendicular to sheet I9 except at the edges and the spots being formed of fibers -2| which are deposited over points I! in inclined positions. The smaller the diameter of rods l6 and the closer these are to the sheet l9 being piled, the more the fibers at the edges of the stripes lean outward and set off the stripes, and the closer points I! are to sheet l9 the more pronounced is the inclination of the fibers in points 2|.

By varying the relative positions of the electrode elements in Figs. 4 and 5 the pattern formed will present various effects. The electrical connections can be varied also. It will be noted ,that while elements II] in Fig. 2 are grounded, elements IS in Fig. 4 are not connected to ground, but are allowed to electrically float on insulating supports (not shown) and to take the voltage resulting from their position in the electric field. If the sheet being piled is held stationary during the deposition of the fibers the pattern will comprise stripes with dots between, but if the sheet is moved during deposition the electrode elements, at least points Il, must move at the same speed as the sheet or streaks will result in the pattern over the points.

Fig. 6 is a plan view of an assembly of electrode elements not unlike the assembly shown in Fig. 5, but in Fig. 6 the bars (similar to those marked IS in Fig. 5) making up member 24 have been Joined together to form a single continuous element. Points 25, one of which is positioned in the center of each individual hexagon, have been found to alter the electric field in such manner that the pile deposited by it comprises hexagon figures of unusual interest. The fibers are inclined at various angles and when looking at the pile from first one and then another position the sheen changes, displaying many fragments of hexagons, some lustrous and some of which are dull. Of course, to provide a closed pattern like the one made with the electrode of Fig. 6, the electrode must participate in any movement undergone by the surface being piled, as will be described, for example, in connection with Fig. 24.

In Fig. 7, elements 3| are strips of insulating material, for instance, of hard rubber or phenol condensation products, attached to a conducting plate 32. Dielectric material with a specific inductive capacity several times that of air, examples of which are porcelain, mica or Bakelite," when placed in an electric field, will locally concentrate the lines of force in the field in the vicinity of the pieces of dielectric. The arrangement shown in Fig. 7 has conducting plate 32 connected through conductor 35 to a source of unidirectional current at a potential of, say, 70,000 volts above ground. Complementary electrode 33 is positioned some 4 inches below member 32 and is maintained at ground potential. Elements 3| are, therefore, positioned in the strong electric field that exists between electrodes 32 and 33. and tend to concentrate the lines of force as they approach electrode 32.

Now if an adhesive covered surface, as sheet 34, that is not conducting, is placed just in front of elements 3| and fibers are suspended in the electric field above electrode 33, or distributed over the surface of electrode 33, many of the fibers will be raised and oriented by the electrical field and attracted to electrode 32. The fibers will move with their long axis parallel to the electric be formed into geometrical figures, letters and the like, thus permitting a wide variety in the patterns formed.

Figs. 8 and 9 illustrate another electrode structure comprising insulating material used with certain embodiments of the invention. It is made up of a conducting base plate 21, conducting elements 28, here shown as narrow strips with rounded tops, and dielectric material 29 between the strips. Electrodes of this construction give very striking results. The sheet to be piled is placed parallel to the top surface of material 29 and touching or closely adjacent the top (exposed) edges of members 28 and a complementary electrode is positioned at a proper distance -2 to 5 inches, depending upon conditionsabove 29 as electrode I2 is positioned above members In in Fig. 2. The pile deposited when a strong electric field is established between the electrodes shows very pleasing shaded stripes, probably due to peculiar distortions in the electric field produced at top of elements 28 where they emerge from insulating material 29. The arrangement of the conductive members with relation to the insulating material has been found to have 9 considerable effect on the patterns produced With the electrode shown in Figs. 8 and 9, very good patterns have been obtained with conducting edges 28 projecting about a; to inch above the surface of dielectric filler 29.

In those embodiments of the invention shown in Figs. 1 to 9, inclusive, the controlling electrode, that is the electrode influencing the pattern in the pile most greatly, is placed just back of the sheet or other member, the surface of which is to be piled. The adhesive coating is placed on the side of the sheet away from the controlling electrode and faces the complementary electrode which furnishes a surface upon which the other end of the electric field terminates. For example, in Fig. 4, elements 16 and I1 comprise the controlling electrode, member 18 is the complementary electrode, and I9 is the sheet being piled with the adhesive coating on the side of the sheet away from electrode l6, [1. Figs. 6, 8 and 9 shown no complementary electrodes, but it is to be understood that in using the controlling electrodes shown in these figures, suitable opposing or complementary electrodes are also used. The electrodes can be positioned so that the fibers move downward to become attached to the coated surface, as in Fig. 2, or the electrodes can be arranged to cause the fibers to move upward as in Fig. 7. The latter arrangement, or an arrangement with vertically positioned surfaces, is advantageous because such arrangements make easy the jarring of loose and poorly attached fibers from the sheet during the piling operation.

The electrode farthest from the sheet is not of such contour, usually, that it influences the pattern in the pile and is often made as a simple, fiat, non-discharging surface. But as will be explained hereinafter, the electrodes away from the sheet to be piled can greatly influence the deposition of the fibers comprising the pile.

The sheet to be piled in Fig. 10 is positioned adjacent an electrode of smooth contour, in this instance, a roll 31 and corona-forming complementary electrodes are responsible for the pattern effect in the pile. It has been found that if the fibers to be electrically deposited are introduced through a tube about which corona discharges are present, desirable results in patterned piles can be obtained. In Fig. 10, sheet 38 travels about a grounded roll 31 which preferably turns to avoid friction and exposes an adhesive covered surface 39 to electrodes 40, each made up of a tube 4| and discharge points 42. It has been found that if wire points 42 are left off when rayon flocks or similar fibers are blown through tubes 4| and the tubes are connected to a source of unidirectional high potential current, the flocks become scattered as they are deposited. Such a result is shown at 43 in Fig. 11. attached to and arranged about high potential tubes 4|, the fiocks are concentrated locally as illustrated in Figs. 12 and 13. If sheet 38 moves while electrodes 40 are stationary, but continuously depositing fibers, stripes 44 are formed. If

the fibers are deposited only while sheet 38 is With points 42 are formed such as those marked 45 in Fig. 13. Other factors controlling the pattern produced are the size of the tubes or nozzles, the velocity of the air'stream, the emphasis given the corona emanating from the points as caused by variously positioning the points about the end of the tube, and the strength of the electric field.

The stripes or points deposited with the electrode assembly in Fig. 10 may be insufficient in themselves to form a pleasing pattern. Advantageously all of surface 39 is covered with adhesive, then spots are first deposited in one color in the manner just described, and then the sheet is moved into another part of the apparatus shown in Fig. 24 where the unpiled surface is covered with fibers of a different color. Not only can the fibers successively deposited be of different colors, but they can be of different length and/or luster, and by controlling the characteristics of the electric field and the length of treatment the spots or stripes can be made to have a very different appearance from the pile filled in between. The furs of certain animals, the silver fox, for instance, can be imitated by using the method just described.

It has been found desirable in the electrical attachment of fibers to form a pile to have the fibers approach the surface to be piled separately, not in clumps or treed together. Screens may be used to break up grouped fibers as they are floated in air streams into the electric field and a simple manner of using a screen or other foraminous member for this purpose is to have it function as one of the electrodes. Figs. 14 and 15 show an electrode 41 that functions as a complementary electrode to grounded electrode 50. Electrode 41 of conducting material is insulated from ground and positioned about four inches below electrode and is connected by conductor 53 to a source of unidirectional high potential current. Itfunctions also to break up clumps of fibers blown by air jets 56 from supply means that are not completely disintegrated by disintegrating means 51. It has been discovered that a foraminous .electrode, positioned and used as is electrode 41 in Fig. 15, can be caused to'infiuence the arrangement of fibers as they are electrically deposited on a surface,on the surface of sheet 52, for example, as it is held adjacent 50. One way of altering the pile formed of the deposited fibers is to make foramin'ous electrode 41 with edges 49-projecting through surface 48 which is preferably of screen. The electric field adjacent edges is so concentrated when a high voltage drop is impressed across electrodes 41 and- 50 that corona discharges emanate from the edges and the fibers just over the edges deposit in other than erect positions as indicated at 5!. Depressed-stripe effects are given the pile formed with electrodes 41 and 50. Of course, points or'edges arranged in patterns could be substituted for edge members 49 in electrode 41.

Figs. 16, 17 and 18 are plan views of fragments of patterned piles which may be made with the controlling electrodes spaced from the surface being piled. The pattern shown in Fig. 16 is made with an electrode of wirenet of coarse mesh to located in the position of elec-. trode 41 in Fig. 15. A very strong electric field is used to deposit the fibers, but not strong enough to force the fibers down into the adhesive, such as results from quite definite corona discharges. The pile in Fig. 17 results from the use of an electrode comprised of parallel wires and that shown in Fig. 18 maybe made with a net of rather small mesh used as a controlling electrode and positioned several inches from the adhesive covered surface being piled. The piles shown in Figs. 16, 17 and 18 are characterized by having lines and/or dots standing out prominently '-as local concentrations of fibers.

Fig. 19 illustrates apparatus in which the field controlling member is supported in front of the surface being piled, but is preferably at the same or nearly the same potential as the electrode just back of the sheet with the surface being piled. Electrode 60 is preferably fiat and is at ground potential. Electrode 64 is of reticulated construction or the like and is maintained at high potential. Sheet 6|, the under side 62 of which is to be piled, is moved through the electric field between electrodes 60 and 64, preferably just under and touching electrode 60, as shown. A mem- -ber 63, advantageously formed as a belt with stencil-like perforations such as the diamond design shown in Fig. 20 or the slots shown in Fig. 21, is moved parallel with and at the same speed as sheet 6|. It is held a short distance, for example one-fourth inch, in front of adhesive covered surface 62. The fibers to be deposited are brought into the apparatus on a moving porous belt 66. When the fibers are carried by belt 66 over the top of wind box 61, compressedair issuing from nozzle 68 and passing through regulating means 69 blows through the interstices of belt 66 and blows the fibers up through electrode 64 and into the electric field for deposition on surface 62. Very definite patterns are made with the apparatus shown in Fig. 19 and they can be made very colorful if the sheet to be piled is passed through several partially shielded fields, each one depositing fibers of a different color.

Belt 63 can be made of wire or other attenuated members woven into a pattern and it will influence the deposition of the fibers comprising the pile by altering the electric field. The resulting patterns will be much like those shown in Figs. 16 and 17, but in more striking relief. Or belt 63 can be made up as a stencil and cause a pattern to be made by definitely covering portions of surface 62 and permitting fiocks to be deposited only behind openings in the stenci Besides the diamond pattern shown in Fig. 20, decorative designs, such as fiowers, and commercial outlines, comprising names, can be formed. Such stencil-like members effect the pattern not only mechanically but also effect it by locally altering the characteristics and intensity of the electric field and therefore they may be designated as field stencils."

Figs. 22 and 23 illustrate apparatus adapted to apply adhesive locally to a surface and then to pile the adhesive covered portions in accordance with the invention. In Fig. 22, adhesive applying roll II has cut away portions I2 and raised portions I3. Only the raised portions carry adhesive to the surface to be piled and in the figure a transverse cross-section of a sheet I5 is shown with strips of adhesive I4 applied thereto by raised portions I3. Fig. 23 shows sheet I5 after having been locally coated with adhesive with roll II passing through a strong electric field between complementary electrodes I6 and I1. Electrode 11 comprises a conducting plate I8 on the bottom surface of which tubes I9, or other members of small surface area which may be but are not necessarily conducting, are attached. Tubes 19 are spaced to correspond with the spacing of raised portions I3 on applicating roll II. Sheet 15 is positioned under and adjacent tubes I9 and, for continuous operation, is moved in a direction parallel to the tubes. The pile 80 deposited on adhesive strips ll, by action of the electric field in the manner previously described, is not uniformly erect, but leans outwardly at the edges and projects into unpiled spaces 8|. The inclined positions of some of the fibers is due to the directions taken by the lines of force of the electric field approaching the surfaces of tubes I9. The efiect of the inclined. fibers partially covering spaces 8I is especially striking when the fibers are of one color and sheet I5 is of another color.

Fig.-24 is a diagrammatic view in side elevation of apparatus which may be used in successively applying the several embodiments of the invention which have been described. A sheet 86 of the material to be piled, for example, a light weight, flexible but closely woven textile, is unwound from supply roll 85, passed over an adhesive applying roll 01, over positioning'and tensioning rolls 90, 9| and 92, and through means, not shown, for finishing and storing the piled product. Roll 81 is shown with raised portions 88 to apply the adhesive from vessel 89 to the surface of sheet 86 in restricted areas only as in that embodiment of the invention illustrated by Figs. 22 and 23. Where the surface of the sheet is to be completely piled, a smooth roll to spread adhesive over the entire surface of the sheet is used.

As the adhesive coated sheet goes over roll 90, it may be sprayed with fibers from one or more spray electrodes I0l in accordance with the practice described in connection with Figs. 10, 11, 12 and 13. If the spray electrodes IOI are operated continuously, lines of fibers are deposited upon sheet 86 as shown in Fig. 12, but if the spraying is done at intervals only, spaced patches such as the spots shown in Fig. 13 will be deposited. The fibers for sprays IOI are supplied through conduit I02 and this can be made to move away from the entrance of sprays IN by reciprocating means, for instance, crank I04 acting, preferably with a quick return movement, through connecting rod I03 will make conduit I02 articulate at joint I05 at the chosen intervals when deposition of particles is to be interrupted. During the period of interruption the fibers blow out the end of conduit I02 and fall to the bottom of easing I06 to be lifted again by blower I01. If electrode IOI is maintained at high potential connecting tube I00 is made of insulating material.

Sheet 86 next passes through an electric field established between screen electrode H0 and control electrode III. The latter electrode can be in the form of any of the control electrodes shown in Figs. 1 to 9 inclusive, but is made into or is attached to an endless hand. If electrode III is to cause the fibers to deposit in a closed pattern or one with transverse marks, it must move at the same speed and in the same direction as sheet 86 while sheet 86 is moving through the electric field above electrode IIO. This is accomplished by turning pulley II2, over which electrode II-I passes, by a positive drive II3 such as a chain from a source of power II4 which also turns pulley 90 over which sheet 86 passes, in positive manner. Positive synchronous movement of belt and electrode can also be obtained by having spursproject from the edge of electrode III and engage perforations along the edges of sheet 86 in the manner known to the moving picture art. A grounded shoe II5 contacts electrode III and maintains it at ground potential.

Underneath sheet 86 a belt IIS may be positioned by utilizing supporting pulley I I! and supporting and propelling pulley II8. Belt II6 may be perforated as a stencil and function as a field stencil in themanner of member 63 in Fig. 19. The stencilling belt must move at the same speed as sheet 86 and such movement is obtained through drive H9. Other field altering means, such as screens, can be used in place of stencilling means IIS, and such means travelling at the speed of sheet 86 will give the pile on sheet 85 a woven appearance as indicated in Figs. 16 and 18. Although pattern control electrode III and stencilling or other field altering means H6 can be used at the same time, ordinarily this is not done. A fiat stationary electrode may be used in place of special electrode II I when a field stencil is being used in front of sheet 86. Fibers are supplied to the field between electrodes III) and III by supply means I 20 in which air jets are utilized to project the fibers up through electrode I I0.

Electrodes I24 and I25 in Fig. 24 are energized and used to deposit fibers if portions of the surface of sheet 86 remain unpiled after the sheet passes through the processing steps described in the above. No special efiect is sought in this last step. Both electrodes have, in general, flat surfaces and the uniform field that results from impressing a high voltage across electrodes I24 and I25 tends to deposit an erect uniform pile.

The deposition of fibers in this step is usually for the purpose of completing the pile started with spray electrodes IOI and/or the pile deposited through field stencil IIB and'this filling is often made with fibers of a difierent color from thatnsed in the preceding steps.

Apparatus for satisfactorily supplying fibers to the field between electrodes I24 and I25 is shown diagrammatically under electrode I24. -It comprises an endless foraminous conveying belt I 26 upon which fibers are spread by a distributor I30, preferably agitated, and a blowing means I21 that distributes air under pressure under belt I26 and causes itto pass up through the belt and raise the fibers therefrom and blow them through screen electrode I24. Undeposited fibers are collected in hopper I28 and conveyed by an airstream set in motion by fan I29 to filter bag collector I3I and thence to distributor I30.

Fig. 24 illustrates apparatus with a wide range of usefulness in the forming of simulated piles on adhesive covered surfaces. It is illustrative of the wide variation in'methods and means for obtaining useful patterns in the electrical deposition of pile forming materials by the local alteration of the characteristics of the electrical field effecting the deposition, so as to produce a definite topical non-uniformity therein. It is obviously subject to a very large degree of variation and may be provided with electrode rapping or agitating means and other devices and modifications.

This application is a division of our applicatio Serial No. 5,288, filed February 6, 1935.

We claim:

1. A patterned pile-surfaced material comprising a base material, a continuous layer of binder material thereon and a substantially continuous coating of fibers having one end embedded in said binder material and the fibers in adjacent areas of said coating having difierent angles of inclination whereby a design of predetermined pattern is formed by the varying reflection of light.

2. A patterned pile-surfaced material comprising a base material, a continuous layer of binder material thereon and a substantially continuous coating of fibers having one end embedded in said binder material and the fibers in said coating locally varying in angle of inclination whereby a design of predetermined pattern is formed by the varying reflection of light.

3. A pile surface material comprising a con-.

'tinuous layer of binder material having fibers embedded therein at one end thereof, said fibers being disposed at locally va y g angles of inclination to form a. design of predetermined pattern by the varying reflection of light.

ARCHIBALD F. MESTON. HARRY A. WINTERMUTE. 

